Elastomeric laminate with activation thickness

ABSTRACT

A method for forming an elastomeric laminate includes the steps of providing a first coverstock material; SELF&#39;ing the first coverstock material to create a pre-SELFed coverstock layer having a primary activation pattern comprising SELF-specific land areas; providing an elastomeric layer; and joining the elastomeric layer to the pre-SELFed layer at zero relative strain, such that the elastomeric layer and pre-SELFed coverstock layer are joined at one or more bonding sites.

FIELD OF THE INVENTION

The present invention relates to a multi-layer elastomeric laminate andarticles including the same.

BACKGROUND OF THE INVENTION

Elastomeric laminates are used in various products including absorbentarticles (e.g., diapers, incontinence articles, feminine hygiene pads),clothing, body wraps, etc. Such laminates typically include anelastomeric layer that provides elasticity to the laminate and an outerlayer (referred to herein as a coverstock layer) that is lessstretchable but suitable for providing durability and desirable tactileproperties. In this way, the laminate permits a component of an articleto closely and comfortably contact the wearer while providing desirableexterior qualities.

Elastic laminates can be produced by multiple methods. For example, thelaminate may be in the form a gathered laminate, wherein the coverstocklayer forms rugosities when the stretchable layer is relaxed. Saidgathered laminates may be formed by extending the stretchable materialto a greater extent than the coverstock material at the time oflamination. Alternatively, the coverstock material may be corrugated andthe elastic material may be in its relaxed state at the time oflamination. In either scenario, following lamination, the coverstockgathers or bunches and forms rugosities when the laminate is in arelaxed state.

Another type of elastomeric laminate is a zero strain laminate. Duringlamination, the coverstock and elastic layers are joined atapproximately zero relative strain (i.e., neither layer is strained to agreater extent than the other layer). Zero strain laminates areactivated by a mechanical straining process, which creates separationsor deformations in the coverstock materials and renders the laminateelastically extensible.

Known elastomeric materials and laminates have limitations. Elasticmaterials alone may not provide desirable tactile properties andtextures required for the end products in which the materials areincorporated. Further, elastic materials can be expensive and limited inthe properties they can provide (e.g., limited in direction ofextensibility, limited in ability to provide differential modulus,etc.). Laminates likewise may lack some desired cost efficiency anddesign versatility. For instance, gathered laminates can be costly tomanufacture due to costs of coverstock materials that are necessary toensure the desired amount of stretch (e.g., if the laminate is tostretch twice its relaxed length, than the coverstock should be twice aslong as the elastic material). Moreover, achieving differentialproperties (e.g., differential modulus) can be challenging and costly asvariations in the elastic material forming the stretchable layer wouldbe necessary (e.g., different strain levels, basis weights,formulations). The manufacturing of zero strain laminates also presentschallenges. The mechanical straining process may result in damage to oneor more layers of the laminate. Indeed, areas of a layer that introducea variation (e.g., a change in material and/or caliper, a bond site, oran imperfection) may result in added stress in said area, leading toweaknesses or tears in the one or more layers or in the laminate as awhole. Increasing the number of layers undergoing activation results ina greater probability that a defect in one or more locations will occur.Further, in plastically deforming the coverstock material, there is arisk that portions of the material may be completely destroyed.Weaknesses and tears can lead to exposure of the elastic material and/orexcess fuzz, both of which could lead to downtime and inefficiencies inmanufacturing, result in product performance issues and/or become acomfort and/or safety issue to the end user. In addition, by mechanicalstraining all layers at once, any defects created will extend throughthe entire laminate. Prevention of these problems often requires moreexpensive coverstock materials and/or slower process rates. Knownlaminates are also limited in the variations in textures, surfacepatterns and related properties that can be created, particularly whereit is desirable to have different textures and patterns on either sideof the laminate.

Therefore, there is a continued need to reduce costs and enhanceefficiency in creating elastomeric laminates. There is a further needfor manufacturing processes that enable differential properties intargeted regions and/or differential properties that can follow targetedpathways in a product. Likewise, it would be beneficial to provideelastomeric laminates with desirable textures on both exterior surfacesand/or that embody different activation patterns on various layers inorder to more fully optimize performance.

SUMMARY OF THE INVENTION

The present invention may address one or more of these problems. In anembodiment, a method for forming an elastomeric laminate includes thesteps of: providing a first coverstock material; SELF'ing the firstcoverstock material to create a pre-SELFed coverstock layer having aprimary activation pattern comprising SELF-specific land areas;providing an elastomeric layer; and joining the elastomeric layer to thepre-SELFed layer at zero relative strain, such that the elastomericlayer and pre-SELFed coverstock layer are joined at one or more bondingsites.

In another embodiment, a method for forming an elastomeric laminateincludes the steps of: providing a first coverstock material; SELF'ingthe first coverstock material to create a pre-SELFed coverstock layerhaving a primary activation pattern comprising SELF-specific land areas;providing an elastomeric layer; elongating one of the elastomeric layerand the pre-SELFed layer to form a strained layer such that strainedlayer comprises a greater strain than the other of elastomeric layer andthe pre-SELFed layer; and joining the elastomeric layer to thepre-SELFed layer, such that the elastomeric layer and pre-SELFedcoverstock layer are joined at one or more bonding sites and form agathered laminate.

In a further embodiment, a method for forming a hybrid gatheredelastomeric laminate includes the steps of: providing a zero strainlaminate; providing a second layer; elongating one of the zero stainlaminate and the second layer to form a strained layer such thatstrained layer comprises a greater strain than a nonstrained layer, thenonstrained layer comprising the other of zero strain laminate and thesecond layer; and joining the zero strain laminate to the second layer,such that the zero strain laminate and second layer are joined at one ormore bonding sites.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic exploded perspective view of a laminate inaccordance with one nonlimiting embodiment of the present invention.

FIG. 2 is a schematic exploded perspective view of a laminate inaccordance with another nonlimiting embodiment of the present invention.

FIGS. 3a-3b are schematic side elevation views of portions of laminatesin accordance with nonlimiting embodiments of the present invention.

FIG. 3c is a schematic side elevation view of a portion of a prior artlaminate.

FIG. 4 is a schematic perspective view of an apparatus and process foractivating a web material in accordance with one nonlimiting embodimentof the present invention.

FIG. 4a is a schematic side elevation view of a portion of a webmaterial as it passes through a nip between a pair of stretching membersduring activation in accordance with one nonlimiting embodiment of thepresent invention.

FIG. 5 is a schematic plan view of an activated web material inaccordance with one nonlimiting embodiment of the present invention.

FIG. 6 is a schematic perspective view of a web material afteractivation in accordance with a nonlimiting embodiment of the presentinvention.

FIG. 7 is a schematic plan view of an activated web material inaccordance with one nonlimiting embodiment of the present invention.

FIG. 8 is a schematic cross-sectional view of the web of FIG. 5 takenalong line 8-8.

FIG. 9 is a schematic side elevation view of a web in accordance withanother nonlimiting embodiment of the present invention.

FIG. 10 is a schematic plan view of a fastener in accordance with onenonlimiting example of the present invention.

FIG. 11 is a schematic perspective view of an elastomeric layer inaccordance with one nonlimiting embodiment of the present invention.

FIG. 12a is a schematic, exploded perspective view of an elastomericlaminate layer in accordance with one nonlimiting embodiment of thepresent invention.

FIG. 12b is a schematic side elevation view of a portion of anelastomeric laminate layer in accordance with one nonlimiting embodimentof the present invention.

FIGS. 13a-13c are schematic side elevation views of portions oflaminates in accordance with nonlimiting embodiments of the presentinvention.

FIG. 14 is a schematic plan view of an activated web material inaccordance with one nonlimiting embodiment of the present invention.

FIG. 15 is a schematic perspective view of an apparatus for activating aweb material in accordance with one nonlimiting embodiment of thepresent invention.

FIGS. 16a-16d are schematic side elevation views of portions oflaminates in accordance with nonlimiting embodiments of the presentinvention.

FIG. 17 is a schematic perspective view of layers of a laminate inaccordance with one nonlimiting embodiment of the present invention.

FIG. 18a is a schematic side elevation view of a portion of a laminatein accordance with another nonlimiting embodiment of the presentinvention.

FIG. 18b is a schematic plan view of layers of a laminate in accordancewith a nonlimiting embodiment of the present invention.

FIG. 19 is a schematic side elevation view of a portion of a laminate inaccordance with one nonlimiting embodiment of the present invention.

FIG. 20 is schematic plan view of an exemplary absorbent articleaccording to one nonlimiting embodiment of the present invention. Theabsorbent article is shown in a flat, uncontracted state.

FIGS. 21a-21b are a schematic cross-sectional view of an exemplaryembodiments of the leg gasketing systems and topsheet of FIG. 20, thecross section taken along line 21-21. The leg gasketing systems areshown in a flat, uncontracted state.

FIGS. 22a-22b are schematic plan views of portions of exemplaryabsorbent articles including exemplary attachment areas in accordancewith nonlimiting embodiments of the present invention.

FIG. 23a is a perspective view of an exemplary absorbent pant accordingto one nonlimiting embodiment of the present invention.

FIG. 23b is a schematic plan view of an exemplary absorbent pantprecursor structure, prior to joining of the front and rear sections ofthe belt.

DETAILED DESCRIPTION OF THE INVENTION

Definitions

“Absorbent article” means a device that absorbs and contains bodyexudates and, more specifically, devices that are placed against or inproximity to the body of the wearer to absorb and contain the variousexudates discharged from the body. Exemplary absorbent articles includediapers, training pants, pull-on pant-type diapers (i.e., a diaperhaving a pre-formed waist opening and leg openings such as illustratedin U.S. Pat. No. 6,120,487), refastenable diapers or pant-type diapers,incontinence briefs and undergarments, diaper holders and liners,feminine hygiene garments such as panty liners, absorbent inserts, andthe like.

“Activation” is the mechanical deformation of a plastically stretchablematerial that results in permanent elongation of the stretchablematerial, or a portion of the stretchable material, in the direction ofactivation in the X-Y plane of the material. For example, activationoccurs when a web or portion of a web is subjected to a stress thatcauses the material to strain beyond the onset of plasticity, which mayor may not include complete mechanical failure of the material orportion of the material. Activation of a laminate that includes anelastic material joined to a plastically stretchable material typicallyresults in permanent deformation of the plastic material, while theelastic material returns substantially to its original dimension.“Activate,” and variations thereof, means subjecting a material to anactivation process. “Pre-activate,” and variations thereof, means toactivate a component prior to lamination of the component with otherlayers. Activation processes include incremental stretching and SELFing.

“Activation thickness” means a depth created in a component byactivation. An activation thickness is the maximum depth of a deformedarea as measured in the z-direction.

“Disposable,” in reference to articles, means that the articles aregenerally not intended to be laundered or otherwise restored or reusedin the same capacity (i.e., they are intended to be discarded after asingle use and, preferably, to be recycled, composted or otherwisediscarded in an environmentally compatible manner).

“Elastic,” “elastomeric,” and “elastically extensible” mean the abilityof a material to stretch by at least 25% without rupture or breakage ata given load, and upon release of the load the elastic material orcomponent exhibits at least 80% recovery (i.e., has less than 20% set).For example, an elastic material that has an initial length of 100 mmcan stretch to at least 150 mm (50% stretch) and, upon removal of theforce, retract to a length of 110 mm (i.e., have a set of 10 mm or 10%).Stretch, sometimes referred to as strain, percent strain, engineeringstrain, draw ratio, or elongation, along with recovery and set may eachbe determined according to the Hysteresis Test described in more detailbelow. It is to be understood; however, that this definition of elasticdoes not apply to materials that do not have the proper dimensions(e.g., not wide enough) to be properly subjected to the Hysteresis Test.Instead, such material is considered to be elastic if it can stretch toat least 25% upon application of a biasing force, and returnsubstantially to its original length (i.e., exhibit less than 20% set)upon release of the biasing force. In certain embodiments, a materialexhibits less than 20% set when stretched without rupture or breakage byabout 50% or more, or about 100% or more, or from about 25% to about200%. In other words, the material is elastically extensible at aspecified strain of about 50% or more, or about 100% or more or fromabout 25% to about 200%.

“Extensible” means the ability to stretch or elongate, without ruptureor breakage, by at least 25%. If a material can undergo the first cycleof the Hysteresis Test described herein (where the specified strain is25%) without rupture, it is extensible. In certain embodiments herein, amaterial comprises extensibility when stretched by about 50% or more, orabout 100% or more, or from about 25% to about 200%. In other words, thematerial can undergo the first cycle of the Hysteresis Test withoutrupture or breakage where the specified strain is about 50% or more, orabout 100% or more, or from about 25% to about 200%.

“Film” means a sheet-like material wherein the length and width of thematerial far exceed the thickness of the material (e.g., 10×, 50×, oreven 1000× or more). Films are typically liquid impermeable but may beconfigured to be breathable.

“Incremental stretching” means a process in which a web material iscontrollably plastically stretched in increments along one or moredirections by being passed under tension between the surfaces of a pairof stretching members having continuously intermeshing ridges andvalleys, or other intermeshing features as described for example, inU.S. Pat. Pub. No. 2013/0082418 and U.S. Pat. No. 5,167,897. Thestretching members may comprise a pair of rollers (e.g., ring rollers),gear-like rollers, belts or plates with continuously intermeshingfeatures. Ring-rolling is a type of incremental stretching.

“Joined” means configurations whereby an element is directly secured toanother element by affixing the element directly to the other element,and configurations whereby an element is indirectly secured to anotherelement by affixing the element to intermediate member(s) that in turnare affixed to the other element.

“Laminate” means two or more materials that are bonded to one another byany suitable method known in the art (e.g., adhesive bonding, thermalbonding, ultrasonic bonding, or high pressure bonding using non-heatedor heated patterned roll).

“Longitudinal” means a direction lengthwise in an article such that thelongitudinal direction may run parallel to the maximum linear dimensionin the x-y plane of the article. In an absorbent article as describedherein, the longitudinal direction runs substantially perpendicular froma waist end edge to an opposing waist end edge when the absorbentarticle is in a flat out, uncontracted state, or from a waist end edgeto the bottom of the crotch in a bifolded article. Directions within 45degrees of the longitudinal direction are considered to be“longitudinal.” “Lateral” refers to a direction running from a side edgeto an opposing side edge of an article and generally perpendicular tothe longitudinal direction. Directions within 45 degrees of the lateraldirection are considered lateral.

“Machine direction” or “MD” is the direction parallel to the directionof travel of the web in a manufacturing process. Directions within 45degrees of the MD are considered to be machine directional. The “crossmachine direction” or “CD” is the direction substantially perpendicularto the MD and in the plane generally defined by the web. Directionswithin 45 degrees of the CD are considered to be cross directional.

“Nonwoven” means a porous, fibrous material made from continuous (long)filaments (fibers) and/or discontinuous (short) filaments (fibers) byprocesses such as, for example, spunbonding, meltblowing, airlaying,carding, coforming, hydroentangling, and the like. Nonwovens do not havea woven or knitted filament pattern. Nonwovens may be liquid permeableor impermeable.

“Relaxed” means the state of an element, material or component at restwith substantially no external force acting on the element, other thangravity.

“SELF” or “structured elastic-like form” means a process in which a webmaterial is controllably plastically stretched in increments along oneor more directions by being passed under tension between the surfaces ofa pair of stretching members having discontinuously intermeshing ridgesand valleys, or other features as described in, for example, U.S. Pat.No. 5,993,432. The stretching members may be a pair of rollers,gear-like members, belts or plates with discontinuous intermeshingfeatures. Pre-SELF components are subjected to the SELF process prior tolamination to or with other components/layers.

“Unactivated,” in reference to a component, means the component as acollective whole has not undergone an activation process. For instance,an unactivated laminate may comprise layers that have been activated,but the laminate as a whole (post-lamination) has not undergone anactivation process.

“Web” means a material capable of being wound into a roll. Webs may befilms, nonwovens, laminates, apertured films and/or laminates, and thelike. The face of a web refers to one of its two dimensional surfaces,as opposed to its edge.

“X-Y plane” means the plane defined by the MD and CD of a moving web orthe length and width of a piece of material. The Z-direction isperpendicular to the X-Y plane.

Overview

The present invention relates to elastomeric laminates having one ormore layers that have been activated prior to lamination, particularlywhere the entire laminate is not subjected to activation post-lamination(i.e., the entire laminate is unactivated).

The laminate 10 may comprise two or more layers 12, a first surface 14and a second surface 16 substantially opposite the first surface 14. Thelaminate further comprises a total thickness, T, which is the greatestz-direction distance between the first surface and the second surface(i.e., the height distance between the highest point on the firstsurface and the lowest point on the second surface when the laminate ispositioned such that its X-Y plane is horizontal). The first and secondsurfaces 14, 16 may be formed by different layers 12. The laminatelayers 12 may comprise at least one coverstock layer 17 and at least oneelastomeric layer 20. The coverstock layer 17 may comprise a pre-SELFedcoverstock layer 18, where the layer 17 is SELFed prior to lamination.In an embodiment, a first pre-SELFed coverstock layer 18 forms the firstsurface 14 and a first elastomeric layer 20 forms the second surface 16of the laminate as shown in FIG. 1. In an alternative embodiment, thefirst and second surfaces 14, 16 are formed by different coverstocklayers (18 a, 18 b) as shown in FIG. 2. At least one of the coverstocklayers 18 a is SELFed prior to lamination.

The SELFing process, as well as other activation processes, creates oneor more activation thicknesses, TA. Every activation thickness in alayer that is pre-activated will be less than the total thickness of thelaminate, T, as shown in FIGS. 3a and 3b . In other words, theactivation thicknesses do not extend through the entire thickness of thelaminate. Comparatively, FIG. 3c is an example of a prior art laminate,where the activation thickness does extend through the entire thicknessof the laminate.

The Pre-SELFed Coverstock Layer

A coverstock layer 17 is generally non-elastic. Coverstock layermaterials 19 may be selected from nonwovens, films and/or any other typeof web-based material. In some embodiments, one or more coverstockmaterials comprise a nonwoven 190. Any suitable nonwoven may be used,including activatable nonwovens. It is typically desirable for theprecursor nonwoven web to have extensibility to enable the fibers tostretch and/or rearrange into the form of the protrusions and maintainat least some non-broken fibers in the sidewalls of the protrusions. Itmay be desirable for the precursor nonwoven to be capable of undergoingan apparent elongation (strain at the breaking force, where the breakingforce is equal to the peak force) of greater than or equal to about oneof the following amounts: 100% (that is double its unstretched length),110%, 120%, or 130% up to about 200%. The MD and CD tensile propertiesare measured using World Strategic Partners (WSP) (harmonization of thetwo nonwovens organizations of INDA (North American based) and EDANA(Europe based)) Tensile Method 110.4 (05) Option B, with a 50 mm samplewidth, 60 mm gauge length, and 60 mm/min rate of extension. Note thatthe gauge length, rate of extension and resultant strain rate are fromdifferent from that specified within the method. Activatable nonwovensmay comprise polypropylene, polyethylene and combinations thereof.

In an embodiment, the laminate 10 comprises a first pre-SELFedcoverstock layer 18. Prior to being joined to another layer 12, thefirst pre-SELFed layer 18 or a portion of said layer may be SELFed asdefined herein. The layer 18 may be SELFed by any suitable method and/orapparatus. Exemplary methods/apparatuses of SELFing are described inU.S. Pat. Nos. 5,891,544; 5,993,432; 5,968,029 with respect to SELF'inglaminates. However, in the present invention said processes are utilizedon the layer 18 prior to lamination. In an embodiment, the coverstockmaterial 18 may be passed through a nip 29 between a pair of rotatingSELF'ing rolls 30 as shown in FIG. 4. Each roll may comprise a series ofridges 31, where the ridges on the first roll 30 a are offset from theridges on the second roll 30 b. In this way, the ridges intermesh as theweb of coverstock material is passed through the nip 29. One or more ofthe ridges 31 on the first roll 30 a and/or the second roll 30 b maycomprise a plurality of notches 32. The intermeshing ridges plasticallydeform the material 18, creating deformed areas 26 (shown as lines onthe web 18 in FIG. 4). Portions of the web coverstock material 18 areleft relative less stretched or substantially intact. These lessstretched or substantially intact areas will be referred herein to asland areas 24, which will be separated by the deformed areas 26.Generally, the land areas 24 are regions that experience little or nolocal straining during activation and therefore, the land areas 24 areregions with little to no localized permanent deformation. On the otherhand, the deformed areas 26 experience local strain during activationand therefore have localized permanent deformation. This deformationprovides increased extensibility in a first extensibility direction, FE,relative to the web's initial extensibility. The first extensibilitydirection, FE, is substantially perpendicular to the direction of theridges 31.

In most activation processes (including SELF), land areas 24 coincidewith areas of the web 18 that contact the tip of the ridges on therespective rolls as shown in FIG. 4a . (FIG. 4a is a partial side viewof a web undergoing activation in an area of the apparatus that does nothave notches 32.) Without being bound by theory, it is believed that theweb 18 is friction-locked about the tip of the ridge and therefore nodeforming force is exerted on the material 18 in that area. Land areascorresponding with areas where the web contacts the tip of theintermeshing ridges will be referred to herein as activation land areas240. Activation land areas 240 follow a continuous directional path, P,through at least a portion of the web 18. Said path, P, is generallyperpendicular to the direction of extensibility of the activatedmaterial, as depicted in FIG. 4 and FIG. 5. For purposes of thisdisclosure, the direction perpendicular to the direction ofextensibility will be referred to as the non-extensible direction, NE.

The SELF process, however, additionally creates SELF-specific land areas242 which occur when the web 18 encounters or passes the notches 32.SELF-specific land areas 242 will follow a continuous directional path,P_(self), through at least a portion of the web 18. Because the notches32 are disposed on the intermeshing ridges 31 in the SELF activationprocess, the path P_(self) is not orthogonal to the direction ofextensibility, FE. Rather, the continuous directional path, P_(Self),extends in substantially the same direction as the direction ofextensibility. The path, P_(self), may be straight as depicted in FIG.5, or may curvilinear as shown in FIG. 6 (where, for example,SELF-specific land areas are offset in the CD and/or MD). P_(self) mayalso be at any non-orthogonal angle relative to the direction ofextensibility (for example within about 45 degrees of the direction ofextensibility) or zig zag as depicted in FIG. 7. As can be seen in FIGS.5-7, the paths (P, P_(self)) may overlap. Essentially, notches 32 in theSELFing process cause deformed areas in the web to be discontinuous inthe non-extensible direction. This lack of continuity in the deformedareas allows for a continuous path of land areas to extend insubstantially the same direction as the direction of extensibility.Other activation processes do not provide deformed areas that arediscontinuous in the non-extensible direction.

SELFing provides extensibility properties that a traditional activationprocess cannot provide. The SELF-specific land areas provide additionaltailoring of the overall extension properties because said SELF-specificland areas inhibit extension locally. In addition, spacing betweennotches 32 on the ridges 31 (i.e., the length between two notches on theridge) may vary, allowing for non-uniform properties (e.g.,extensibility) within the web 18. Further, the SELF-specific land areas242 also contribute to unique three-dimensional textures that are notpossible without the notches.

In SELF activation, the notches 32 and intermeshing features 31 may bedisposed on the stretching members 30 in a SELF pattern to form patternsof land areas 24 on a material. Exemplary patterns that can be createdthrough SELFing are depicted in U.S. Pat. Nos. USD402,121, USD673,746.The orientation and arrangement of the land areas 24 with respect to theextensibility direction affects the degree of extensibility. Forexample, a curvilinear or a zigzag P_(Self) as in FIG. 6 or 7 willprovide greater extensibility than a substantially straight path,P_(self), in the same web. Likewise, a linear P_(Self) that is narrower(as measured in the nonextensibility direction as the distance betweendeformed areas) will provide greater extensibility than a linearP_(Self) that is wider, and a linear P_(self) disposed at an angle withrespect to the direction of extensibility will provide greaterextensibility than a linear P_(self) that is parallel to the directionof extensibility. By greater extensibility, it is meant that a materialwill elongate without rupture at greater levels of strain.

Turning to FIGS. 8-9, the pre-SELFed layer 18 may comprise one or moreactivation thicknesses, TA. Where layer comprises multiple activationthicknesses, those thicknesses may vary in dimensions. Additionally oralternatively, some activation thicknesses may have the same dimensions.Variation in multiple activation thicknesses may arise in the MD and/orin the CD. Importantly, all of the activation thicknesses, TA, will beless than the total thickness of the laminate 10.

In an embodiment, the pre-SELFed coverstock layer 18 comprises a primaryactivation pattern 28. The primary activation pattern 28 includesSELF-specific land areas 242 that follow a continuous directional path,P_(self), in the first extensibility direction, FE. In one nonlimitingexample, the first extensibility direction, FE, is substantially thesame as the cross machine direction.

The activation pattern 28 may comprise a uniform design 28 a in MDand/or in the CD. In one nonlimiting example, the notch-to-notch spacingin one or more directions on the stretching members 30 may be uniformresulting in substantially uniform spacing of the SELF-specific landareas 242 in one or more directions as shown in FIG. 8. In a furthernonlimiting example, the remaining activation land areas 240 may beuniformly spaced. Additionally or alternatively, in a uniform pattern 28a, activation thicknesses corresponding to SELF-specific land areasand/or activation thicknesses corresponding to non SELF-specific landareas may be the same.

In another nonlimiting example, the activation pattern 28 is non-uniformin the X-Y plane and/or in the z-direction. An exemplary non-uniformpattern 28 b is shown in FIG. 9 where the deformed areas comprisedifferent z-direction heights. Additionally or alternatively, anon-uniform pattern 28 b may comprise varied spacing in the MD and/or CDas shown in FIG. 10. (FIG. 10 is a schematic representation of afastener 544 with zones delimited by dotted lines.) Non-uniform patterns28 b may be particularly useful where differential properties aredesired within the layer. For instance, a non-uniform pattern may createdifferential modulus resulting from deformed areas 26 being disposedinconsistently throughout the pattern 28 b. FIG. 10 provides anon-limiting example of this concept by illustrating different designsrendering differential modulus (and/or other properties) between zonesZ1, Z2, and Z3. A non-uniform pattern 28 b may also create differingaesthetics throughout the pattern 28 b, which may result in a desirabledesign.

The Elastomeric Layer

The laminate 10 further comprises an elastomeric layer 20. Theelastomeric layer 20 comprises one or more elastomeric materials 22which provide elasticity to at least a portion of the layer 20.Nonlimiting examples of elastomeric materials 22 include film (e.g.,polyurethane films, films derived from rubber and/or other polymericmaterials), elastic strands (e.g., LYCRA® strand, natural and/orsynthetic rubber), an elastomeric coating applied to another substrate(e.g., a hot melt elastomer, an elastomeric adhesive, printed elastomeror elastomer co-extruded to another substrate), elastomeric nonwovens,scrims. Elastomeric materials can be formed from elastomeric polymersincluding polymers comprising styrene derivatives, polyesters,polyurethanes, polyether amides, polyolefins, combinations thereof orany suitable known elastomers including but not limited to co-extrudedVISTAMAXX®. Exemplary elastomers and/or elastomeric materials aredisclosed in U.S. Pat. Nos. 8,618,350; 6,410,129; 7,819,853; 8,795,809;7,806,883; 6,677,258 and U.S. Pat. Pub. No. 2009/0258210. Commerciallyavailable elastomeric materials include KRATON (styrenic blockcopolymer; available from the Kraton Chemical Company, Houston, Tex.),SEPTON (styrenic block copolymer; available from Kuraray America, Inc.,New York, N.Y.), VECTOR (styrenic block copolymer; available from TSRCDexco Chemical Company, Houston, Tex.), ESTANE (polyurethane; availablefrom Lubrizol, Inc, Ohio), PEBAX (polyether block amide; available fromArkema Chemicals, Philadelphia, Pa.), HYTREL (polyester; available fromDuPont, Wilmington, Del.), VISTAMAXX (homopolyolefins and randomcopolymers, and blends of random copolymers, available from EXXONMobile, Spring, Tex.) and VERSIFY (homopolyolefins and randomcopolymers, and blends of random copolymers, available from Dow ChemicalCompany, Midland, Mich.).

In an embodiment shown in FIG. 11, the elastomeric layer 20 comprises aninherently elastomeric material 220. Nonlimiting examples of inherentlyelastomeric materials include rubber and stretchable films or filaments(e.g., SPANIDEX®, LYCRA®). In another embodiment, the elastomeric layer20 comprises an activated elastomeric material 222 (i.e., a materialthat becomes elastomeric or enhances its elasticity through activation)as shown in FIGS. 12a-12b . The activated elastomeric material 222 isactivated prior to being joined to the pre-SELFed layer 18.

In a further embodiment, the elastomeric layer 20 may comprise anelastomeric laminate layer 224. The elastomeric laminate layer 224 maycomprise two elastomeric materials 22 joined together (e.g., twoinherently elastomeric materials 220 joined together). As shown in FIGS.12a and 12b , the elastomeric laminate layer 224 may comprise anelastomeric material 22 joined to a coverstock material 19 (e.g., anonwoven 190) and subsequently activated to form an activatedelastomeric material 222.

In embodiments involving activated elastomeric materials, saidactivation forms one or more elastomeric layer activation thicknesses,TA_(E). The activated elastomeric material 222 may be activated by anysuitable means. In one nonlimiting example, the activated elastomericmaterial 222 undergoes a ring-rolling process (as described in moredetail below). In another nonlimiting example, the activated elastomericmaterial 222 undergoes a SELF process. In such nonlimiting example, theSELF pattern utilized may be the same or it may be different from theSELF pattern utilized on the pre-SELFed coverstock layer 18. In afurther nonlimiting example, the deformed areas and/or land areas of anactivated elastomeric layer 222 may be at least partially aligned, orsubstantially fully aligned, with the deformed areas and/or land areasof the pre-SELFed coverstock layer 18 as shown in FIG. 13a . In anothernonlimiting example, there may be a random association of land areas anddeformed areas between the layers 18, 20 as shown in FIG. 13b . In analternative nonlimiting example, the land areas and deformed areas ofthe respective layers may be offset as shown in FIG. 13 c.

In some embodiments, the laminate 10 may comprise activationthickness(es) on two different layers—at least one activation thickness,TA, formed on the pre-SELFed coverstock layer 18 and at least anotheractivation thickness, TA_(E), formed on the elastomeric layer. None ofthe activation thicknesses (TA, TA_(E)) extend throughout the totalthickness, T, of the laminate 10. Said differently, each activationthickness is less than the total thickness.

Additional Layers

The laminate may include more than two layers 12. In one nonlimitingexample (discussed above), the elastomeric layer 20 may comprisemultiple layers that have been joined together prior to the elastomericlayer 20 being joined with the pre-SELFed coverstock layer 18. In otherembodiments, additional layers 12 may include additional elastomericlayers 20 and/or added coverstock layers 17. Each additional layer 12may be inherently extensible or activated, provided that at least onelayer in the laminate is pre-SELFed and that the laminate comprises anactivation thickness, TA, that is less than the total thickness of thelaminate, T. The additional layers 12 may be used to optimize the totalstrength, extensibility and/or other functionalities of the laminate 10.In one nonlimiting example, two or more separate coverstock layers 17may be added to one or both sides of the stretchable material. In thisway, additional strength and/or texture may be provided to the laminate10.

In one nonlimiting example, the laminate comprises a pre-SELFedcoverstock layer 18 and a second pre-activated coverstock layer 180. Thefirst surface 14 of the laminate may be formed by the pre-SELFedcoverstock layer 18 and the second surface 16 may be formed by secondpre-activated coverstock layer 180. The second pre-activated coverstocklayer 180 may be extensible in a second extensibility direction, SE. Thesecond extensibility direction, SE, may be the same as or different thanthe first extensibility direction, FE. An exemplary second pre-activatedcoverstock layer is depicted in FIG. 14. In some embodiments, the degreeof extensibility in the pre-SELFed layer differs from the degree ofextensibility of the second pre-activated layer 180 in one or moredirections.

The second pre-activated layer 180 may comprise a secondary activationpattern 280. The secondary activation pattern 280 may be formed by anysuitable means of activation. In an embodiment, the second pre-activatedcoverstock layer 180 is activated by ringrolling (see FIG. 14 showing aring rolled web and FIG. 15 depicting ring rolling equipment).Ring-rolling typically comprises stretching members with continuouslyintermeshing features (e.g., intermeshing ridges 31). Compared to theabove-described SELF'ing embodiment, the intermeshing features ofstretching members (shown as rollers 300 a, 300 b in FIG. 15) in aring-rolling process are void of notches 32. In this way, theintermeshing features continuously intermesh the web 180 (e.g., ridges),resulting in deformed areas and activation land areas. As discussedabove, the activation land areas 240 will not follow a continuous pathin the direction of extensibility of the layer 180. Rather, theactivation land areas 240 will typically follow a continuous path in thenon-extensible direction, NE.

In an alternative embodiment, the second pre-activated coverstock layer180 comprises a second pre-SELFed coverstock layer 18 b, such that thelaminate 10 comprises two pre-SELFed coverstock layers 18, 18 b and oneor more elastomeric layers 20 sandwiched between said pre-SELFedcoverstock layers 18 a, 18 b. In such nonlimiting example, the SELFpattern utilized on the second pre-SELFed coverstock layer 18 b may bethe same or it may be different from the SELF pattern utilized on thefirst pre-SELFed coverstock layer 18 a. In a further nonlimitingexample, the deformed areas and/or land areas of the second pre-SELFedcoverstock layer 18 b may be at least partially aligned, orsubstantially fully aligned, with the deformed areas and/or land areasof the first pre-SELFed coverstock layer 18 a as shown in FIG. 16a(showing partial alignment). In another nonlimiting example, there maybe a random association of land areas and deformed areas between thelayers 18 a, 18 b as shown in FIG. 16b . In an alternative nonlimitingexample, the land areas and deformed areas of the respective layers maybe offset as shown in FIG. 16c . As explained above, SELF-specific landareas 242 coincide with notches 32 on a stretching member and thereforecan follow a continuous directional path in substantially the samedirection as the direction of extensibility, SE, for at least a portionof the second pre-SELFed coverstock layer 18 b. The secondary pattern280 formed on a second pre-SELFed coverstock layer 18 b may alsocomprise activation land areas 240 that do not follow a continuousdirectional path in the second extensibility direction, SE. Similar tothe first pre-SELFed layer, a second pre-SELFed layer 18 b may comprisea uniform design in MD and/or in the CD, a non-uniform design in the MDand/or the CD or combinations thereof. Any suitable SELF pattern may beutilized.

The second pre-activated layer 180 may comprise one or more secondactivation thicknesses, TA′, as illustrated in FIGS. 16a-d . The secondactivation thickness, TA′, may be the same as or may be different thanone or more activation thicknesses, TA, in the first pre-SELFedcoverstock layer 18.

The primary activation pattern 28 and the secondary activation pattern280 may be the same. Alternatively, the primary pattern and thesecondary pattern may differ by: the shape of the land areas, shape ofthe deformed areas, size of the land areas, size of the deformed areas,number of land areas, type of land areas (i.e., activation,SELF-specific), number of deformed areas, location of land areas,location of deformed areas, pattern uniformity, or combinations thereof.

Each pattern 28, 280 results in certain extensibility capability in thelongitudinal and lateral directions of the laminate and certain strength(e.g., extension force, tear strength). When the laminate 10 comprisesboth patterns 28, 280, a combination of properties from the two patternsis obtained. Said combination is not obtainable from the individualpatterns used alone. Further, even offsetting the same pattern on onelaminate surface relative to the other surface can create differentproperties in different sections of the laminate. The ability to createdifferential properties in the laminate is furthered by non-uniformpatterns or two or more patterns disposed on one layer. Nonlimitingexamples of creating differential properties by varying activationpatterns in areas of a laminate are disclosed in U.S. Pat. Nos.8,858,523; 8,598,407; 8,568,382 and U.S. Pat. App. Nos. 2007/0142815 and2007/0287982 A1.

Further, in another embodiment shown in FIG. 16d , the laminate 10 maycomprise a first pre-SELFed coverstock layer 18, an activatedelastomeric laminate layer 222 and a second pre-activated layer 180,each layer having an activation thickness (TA, TA_(E), TA′) that is lessthan the total thickness of the laminate, T.

The land areas and/or deformed areas in the various layers 12 may bepartially aligned, substantially fully aligned, offset, randomlyassociated or a combination thereof. Activation thicknesses within alayer may be the same or different. Activation thickness in one layer 12may be the same as or different from an activation thickness in anotherlayer 12. Moreover, deformed areas 26 may be oriented outwardly as shownfor example in layer 18 a in FIG. 16d or inwardly as shown in layer 18 bin the same Figure. Any workable combination of inwardly and outwardlyoriented deformed areas are within the scope of the present disclosure.In some embodiments, both outermost layers comprise outwardly facingdeformed areas (i.e., the apex of the deformed area faces away from theinterior of the laminate). Outwardly facing deformed areas may providedesirable textures and/or designs.

Laminate

The laminate 10 is formed by joining the various layers 12. The layers12 may comprise the same dimensions (e.g., area, length, width, shape)or one or more different dimensions. In one embodiment shown in FIG. 17,the laminate is a zero strain laminate 100, wherein the layers 12 arejoined while under substantially the same strain levels, or havingstrain levels that differ by about 5% or less, or about 2% or less. Forexample, the first layer 12 may comprise a first strain, ε₁, and thesecond layer 12 may comprise a second strain, ε₂; the first and secondstrain levels may differ by about 5% or less at the time of lamination.In other words, the layers 12 are laminated at near zero relativestrain. In one nonlimiting example, each layer 12 is in relaxed stateduring lamination, thus forming a zero strain laminate 100.

In additional embodiments shown in FIGS. 18a-18b , the laminatecomprises a gathered laminate 200, wherein one of the layers 12 a isstrained to a greater degree than a remaining layer 12 duringlamination. Stated differently, the strained layer 12 a may comprise afirst strain, ε₁, and the remaining layer 12 b may comprise a secondstrain, ε₂. At the time of lamination, the first strain may be greaterthan the second strain. In this way, the less stretchable layer (e.g.,the coverstock layer 17) will form gathers when the laminate 10 is in arelaxed state. A layer 12 a may be strained more than another by, forexample, elongating the layer 12 a. In one nonlimiting example, thestrained layer 12 a comprises an elastomeric layer 20. In anothernonlimiting example, the strained layer 12 a comprises the coverstocklayer 17, including for example the pre-SELFed coverstock layer 18. Thestraining of the coverstock layer causes necking. Regardless of whetherthe strained layer 12 a comprises an elastomeric layer 20 or acoverstock layer 17, corrugations will form in the coverstock(nonelastomeric) layer when the subsequently formed laminate 200 is in arelaxed state.

In yet another embodiment shown in FIG. 19, the laminate 10 may comprisea hybrid gathered laminate 300. The hybrid laminate 300 may comprise twoor more layers joined at zero relative strain to form a zero strainlaminate 100 which is subsequently joined with one or more layers 12 inthe way that a gathered laminate is formed. The zero strain laminate 100may be activated prior to lamination with another layer. In onenonlimiting example, the zero strain laminate 100 comprises anelastomeric laminate layer 224. In still another nonlimiting example,the zero strain laminate 100 comprises a laminate of a coverstock layer17 and an elastomeric layer 20. In a further nonlimiting example, thestrained layer 12 a comprises the zero strain laminate 100. In anothernonlimiting example, the strained layer 12 a comprises the one or morelayers 12 to which the zero strain laminate 100 is joined. In either ofthe two preceding nonlimiting examples, the non-elastomeric (or lessstretchable layer) will form gathers after lamination.

The layers 12 of the laminate 10 may be joined by any suitable meansincluding but not limited to bonding by adhesive, thermal bonds,ultrasonic bonding, pressure bonding and/or other mechanical attachment.The layers 12 may be joined at one or more bond sites 400. In anembodiment, two or more of the laminate layers 12 are joined byuniformly bonding, where the bond sites are evenly and/or regularlydistributed throughout any area or the entire laminate. Alternatively,or in addition, two or more laminate layers 12 may be joined bynonuniform bonding where the bond sites 400 are distributed in greaterconcentrations in certain regions, possibly resulting in differentialmodulus and/or preventing debonding of the layers especially along theedges. In a further embodiment, one or more bond sites 400 may bealigned with a pattern 28, 280 and/or with one or more land areas 24,and/or with one or more deformed areas 26. Alignment can be achieved byany suitable means known in the art including but not limited toregistration.

The laminate is extensible in one or more directions. The laminate isextensible in the first extensibility direction, FE. The laminate may beextensible in the second extensibility direction, SE, as well. Thedegree of extensibility in the first direction may vary from the degreeof extensibility in the second direction. In some embodiments, thesecond extensibility direction, SE, is caused by additional layers(i.e., the first extensibility direction is due to the properties of afirst layer and the second extensibility direction is due to theproperties of a second layer). In such embodiments, the first and secondextensibility directions may be the same or may differ. In onenonlimiting example, the first extensibility direction, FE, is fromabout 10° to about 110°, or from about 45° to about 90° with respect tothe second extensibility direction, SE, reciting for each range every 5°interval therein. The surfaces 14, 16 of the laminate may comprisepatterns of land areas 28, 280. Land areas within the patterns mayfollow continuous directional paths in the same direction or differentdirections. One or more of the patterns 28, 280 may comprise land areasthat follow a continuous directional path in substantially the samedirection as a direction of extensibility FE, SE.

In some embodiments, the laminate 10 is extensible when stretched byabout 50% or more, or about 100% or more, or from about 25% to about200%. In other words, the laminate can undergo the first cycle of theHysteresis Test described herein without rupture or breakage where thespecified strain is about 50% or more, or about 100% or more, or fromabout 25% to about 200%, reciting for each range every 10% incrementtherein.

The laminate 10 is elastomeric through at least a portion of its area.In some embodiments, the entire lateral dimension of the laminate iselastomeric. In other embodiments, a portion of at least one edge isnon-elastomeric; in this way, said edge of the laminate 10 or laminatelayer 12 can be more effectively secured to other portions of theproduct, in order to prevent debonding over time.

The laminate 10 comprises a total laminate thickness, T, measured as thegreatest z-directional distance from the first surface 14 to the secondsurface 16. The laminate 10 also comprises one or more activationthicknesses, TA, which correspond to the depths created by activatingone or more layers 12 as discussed in detail above. Each activationthickness, TA, is less than the total laminate thickness, T. Thelaminate 10 is not activated once all layers 12 are assembled and joinedinto the final laminate 10, as doing so would destroy or damage existingland areas 24 and undermine the benefits of layer-specific activationand thicknesses.

Typically, laminates are activated post-lamination and therefore eachlayer is affected by the activation process, which can lead to severalundesirable issues. For instance, elastomeric layers 20 (which may lackthe strength of coverstock layers 17) may be damaged in the process.Likewise, localized defects or properties differences within one or morelayers can cause stress risers that, during activation, may lead toundesired weaknesses and/or tears in the final laminate. The more layersbeing activated, the greater the probability that a stress riser willcause a weakness/tear in one or more locations or layers of thelaminate. Further, a defect will be concentrated in a specific locationthrough the depth of the entire laminate, making the laminate weaker.Further still, because the pattern of activation through each layer isidentical, designing the desired overall performance (e.g., areas ofstretch, areas of strength) of the laminate is limited by the selectedpattern. Moreover, while activation can create a texture in a pattern,in some executions, the pattern on the first surface of the laminate maybe the inverse (i.e., mirror image) of the pattern of the secondsurface. As such, areas lacking in softness or cushion on one surfacewill likewise lack softness/cushion on the opposite surface.

The present invention avoids one or more of these issues. By activatinglayers separately, fewer layers are activated at once, reducing thelikelihood of stress risers and localized defects concentratedthroughout the depth of the laminate and/or providing the ability tooptimize activation process conditions for each layer (e.g., matchingprocess conditions to material types). Further, the present inventionpermits a greater degree of freedom in selecting activation patterns fordifferent layers of the laminate, which in turn leads to enhancedcustomization to achieve desired benefits. The pattern on one surface 14of the laminate does not have to be the inverse of the pattern on thesecond surface 16. Thus, for example, the pattern on the first surface14 may comprise areas of z-directional loft coinciding with areas of lowcaliper on the opposite surface 16 (the areas of low caliper resultingfrom the pattern selected for the second surface 16). Likewise, eachsurface can comprise textures that can be varied in specific areas toenhance comfort for users. Moreover, varying the textures between layerscan result in differential modulus in targeted regions. In addition,differential modulus can be made to follow targeted pathways in a givenproduct by using different activation (e.g., SELF) patterns in differentlocations of the product and/or laminate as discussed above.Layer-specific activation allows more effective balance of strength,modulus, extensibility and texture in the laminate.

In addition, pre-SELFing the coverstock layer 18 allows for more complextextural designs even in gathered laminates, which typically comprisegathers as the single signature look. With the present invention, thepre-SELFed coverstock layer 18 and/or second pre-activated layer 180 maycomprise three-dimensionally patterned material that is then gathered onthe laminate. Said three-dimensional pattern can create aestheticallypleasing and/or functional variation (e.g., strength, modulus,extensibility). Further, unlike known gathered laminates, a gatheredlaminate 200 of the present invention can achieve extensibility levelsthat are not contingent on the amount of coverstock material used. Theamount of stretch in a traditional gathered laminate is directly linkedto the length of the coverstock layer. For example, if the laminate isexpected to stretch twice the length of its relaxed length, then thecoverstock material layer must be about twice the length of theelastomeric layer. Here, however, activation permits greater stretchwithout using as much coverstock material.

Articles

A laminate in accordance with the present disclosure may be utilized invarious articles, including but not limited to stretchable bandages,stretchable body wraps and shape wear, packaging materials and absorbentarticles. In some embodiments, an article comprising the laminate 10 isdisposable. In some embodiments, a disposable absorbent articlecomprises the laminate 10. In still further embodiments, more than onelaminate 10 is used in a single article. In such embodiments, thelaminates 10 may have the same or different properties.

FIG. 20 is a plan view of an exemplary, non-limiting embodiment of anabsorbent article 500 of the present invention in a flat, uncontractedstate. The body-facing surface 502 of the absorbent article 500 isfacing the viewer. The absorbent article 500 includes a longitudinalcenterline 510 and a lateral centerline 520, two longitudinal edges 512,and a front waist edge 513 opposite a back waist edge 514. The absorbentarticle 500 comprises a chassis 522. The absorbent article 500 andchassis 522 are shown to have a first waist region 536, a second waistregion 538 opposed to the first waist region 536, and a crotch region537 located between the first waist region 536 and the second waistregion 538. The waist regions 536 and 538 generally comprise thoseportions of the absorbent article 500 which, when worn, encircle thewaist of the wearer. The crotch region 537 is the portion of theabsorbent article 500 which, when the absorbent article 500 is worn, isgenerally positioned between the legs of the wearer.

The chassis 522 may comprise a liquid permeable topsheet 524, abacksheet 526, and an absorbent core 528 between the topsheet 524 andthe backsheet 526. The topsheet 524 may be joined to the core 528 and/orthe backsheet 526. The backsheet 526 may be joined to the core 528and/or the topsheet 524. It should be recognized that other structures,elements, or substrates may be positioned between the core 528 and thetopsheet 524 and/or backsheet 526, including but not limited to anacquisition-distribution system. In certain embodiments, the chassis 522comprises the main structure of the absorbent article 500 with otherfeatures added to form the composite absorbent article structure. Whilethe topsheet 524, the backsheet 526, and the absorbent core 528 may beassembled in a variety of well-known configurations, absorbent articleconfigurations are described generally in U.S. Pat. Nos. 3,860,003;5,151,092; 5,221,274; 5,554,145; 5,569,234; 5,580,411; and 6,004,306.Additional nonlimiting examples of suitable configurations are describedin U.S. Pat. Nos. 5,575,783; 5,242,436; 5,499,978; 5,507,736; and5,368,584.

The laminate 10 may be joined to the chassis 522 and/or may be a portionof a component that is joined to the chassis 522. The laminate 10 may bedisposed in one of the first waist region, second waist region, and/orcrotch region. Nonlimiting examples of components comprising thelaminate include a side panel (such as an ear 542), a leg cuff 571,elastic waist feature 581 and a hip panel 596.

In some embodiments, the laminate 10 can be used to provide stretch andthe aforementioned benefits in the chassis 522. At least a portion ofthe topsheet 524 and/or at least a portion of the backsheet 526 maycomprise a laminate 10 of the present invention in order to providestretch to the chassis. In one nonlimiting example, a coverstockmaterial such as a nonwoven is pre-SELFed in accordance with the presentdisclosure and subsequently joined to a stretchable material to form alaminate 10 which is then incorporated into or becomes a portion of thetopsheet 524 or a portion of the backsheet 526.

In some embodiments, a portion of the backsheet 526 and/or portion ofthe topsheet 524 may be used as a part of the laminate 10. In such case,said portion of the backsheet 526 and/or said portion of the topsheet524 may comprise a coverstock layer 17. In one nonlimiting example, thecoverstock layer 17 comprises the backsheet 526, in particular an outercover 526 a of the backsheet 526. In such nonlimiting example, theelastomeric layer 20 may superpose the entire outer cover or a portionof the outer cover. Further, in such embodiments, the core 528 may bewithin, over or under the laminate 10 but unattached to the elastomericlayer. In this way, stretch is not limited by the materials within thecore, allowing greater stretch and conformity to the wearer's body. Anexemplary manner of attaching the core to avoid interference withstretch laminates is disclosed in U.S. Pat. Nos. 8,124,828, 8,569,571,and 5,575,783.

Topsheet:

The topsheet 524 may be positioned at least in partial contact or closeproximity to a wearer. Suitable topsheets 524 may be manufactured from awide range of materials, such as porous foams; reticulated foams;apertured plastic films; or woven or nonwoven webs of natural fibers(e.g., wood or cotton fibers), synthetic fibers (e.g., polyester orpolypropylene fibers), or a combination of natural and synthetic fibers.The topsheet 524 is generally supple, soft feeling, and non-irritatingto a wearer's skin. Generally, at least a portion of the topsheet 524 isliquid pervious, permitting liquid to readily penetrate through thethickness of the topsheet 524. One topsheet 24 useful herein isavailable from BBA Fiberweb, Brentwood, Tenn. as supplier code055SLPV09U. The topsheet 524 may be apertured.

Any portion of the topsheet 524 may be coated with a lotion or skin carecomposition as is known in the art. Non-limiting examples of suitablelotions include those described in U.S. Pat. Nos. 5,607,760; 5,609,587;5,635,191; and 5,643,588. The specific examples are not limiting, as anylotion or skin care composition known in the art may be utilized. Thetopsheet 524 may be fully or partially elasticized or may beforeshortened so as to provide a void space between the topsheet 524 andthe core 528. Exemplary structures including elasticized orforeshortened topsheets are described in more detail in U.S. Pat. Nos.4,892,536; 4,990,147; 5,037,416; and 5,269,775.

Absorbent Core:

The absorbent core 528 may comprise a wide variety of liquid-absorbentmaterials commonly used in disposable diapers and other absorbentarticles. Examples of suitable absorbent materials include comminutedwood pulp, which is generally referred to as air felt creped cellulosewadding; melt blown polymers, including co-form; chemically stiffened,modified or cross-linked cellulosic fibers; tissue, including tissuewraps and tissue laminates; absorbent foams; absorbent sponges;superabsorbent polymers; absorbent gelling materials; or any other knownabsorbent material or combinations of materials. In one embodiment, atleast a portion of the absorbent core is substantially cellulose freeand contains less than 10% by weight cellulosic fibers, less than 5%cellulosic fibers, less than 1% cellulosic fibers, no more than animmaterial amount of cellulosic fibers or no cellulosic fibers. Itshould be understood that an immaterial amount of cellulosic materialdoes not materially affect at least one of the thinness, flexibility,and absorbency of the portion of the absorbent core that issubstantially cellulose free. Among other benefits, it is believed thatwhen at least a portion of the absorbent core is substantially cellulosefree, this portion of the absorbent core is significantly thinner andmore flexible than a similar absorbent core that includes more than 10%by weight of cellulosic fibers. The amount of absorbent material, suchas absorbent particulate polymer material present in the absorbent coremay vary, but in certain embodiments, is present in the absorbent corein an amount greater than about 80% by weight of the absorbent core, orgreater than about 85% by weight of the absorbent core, or greater thanabout 90% by weight of the absorbent core, or greater than about 95% byweight of the core. The absorbent material 528 may be at least partiallysurrounded by a core wrap.

In some embodiments, the core may comprise one or more channels 529,which are substantially free of absorbent material. In one nonlimitingexample, one or more channels may extend longitudinally.

Nonlimiting exemplary absorbent structures for use as the absorbent core528 are described in U.S. Pat. Nos. 4,610,678; 5,260,345; 5,387,207;5,397,316; 5,625,222, 8,979,815, 9,060,904, and 9,072,634; and U.S.patent application Ser. No. 13/491,642.

As disclosed above, in some embodiments, a laminate 10 is not attachedto the absorbent core 528. In this way, the materials of the absorbentcore 528 do not counteract or otherwise interfere with the ability ofthe laminate 10 to stretch.

Backsheet:

The backsheet 526 is generally positioned such that it may be at least aportion of the garment-facing surface 504 of the absorbent article 500.Backsheet 526 may be designed to prevent the exudates absorbed by andcontained within the absorbent article 20 from soiling articles that maycontact the absorbent article 20, such as bed sheets and undergarments.The backsheet 526 is impervious to liquids. Suitable backsheet 526materials include films such as those manufactured by TredegarIndustries Inc. of Terre Haute, Ind. and sold under the trade namesX15306, X10962, and X10964. Other suitable backsheet 26 materials mayinclude breathable materials that permit vapors to escape from theabsorbent article 500 while still preventing exudates from passingthrough the backsheet 526. Exemplary breathable materials may includematerials such as woven webs, nonwoven webs, polymeric films such asthermoplastic films of polyethylene or polypropylene, compositematerials such as film-coated nonwoven webs, and microporous films suchas manufactured by Mitsui Toatsu Co., of Japan under the designationESPOIR NO and by EXXON Chemical Co., of Bay City, Tex., under thedesignation EXXAIRE. Suitable breathable composite materials comprisingpolymer blends are available from Clopay Corporation, Cincinnati, Ohiounder the name HYTREL blend P18-3097. Such breathable compositematerials are described in greater detail in PCT Application No. WO95/16746 and U.S. Pat. No. 5,865,823. Other breathable backsheetsincluding nonwoven webs and apertured formed films are described in U.S.Pat. No. 5,571,096. An exemplary, suitable backsheet is disclosed inU.S. Pat. No. 6,107,537. Other suitable materials and/or manufacturingtechniques may be used to provide a suitable backsheet 526 including,but not limited to, surface treatments, particular film selections andprocessing, particular filament selections and processing, etc. In onenonlimiting example, the backsheet is a thermoplastic film having athickness of from about 0.012 mm to about 0.051 mm.

Backsheet 526 may also consist of more than one layer. The backsheet 526may comprise an outer cover 526 a and an inner layer 526 b. The outercover may be made of a soft, non-woven material. The inner layer may bemade of a substantially liquid-impermeable film, such as a polymericfilm. The outer cover and an inner layer may be joined together byadhesive or any other suitable material or method. A particularlysuitable outer cover is available from Corovin GmbH, Peine, Germany assupplier code A18AH0, and a particularly suitable inner layer isavailable from RKW Gronau GmbH, Gronau, Germany as supplier codePGBR4WPR.

Turning to FIG. 21a , the backsheet may comprise one or more laminates10 of the present invention. In some embodiments, the outer cover 526 aforms a layer of the laminate 10. In one nonlimiting example, the outercover 526 a or portion(s) of the outer cover are pre-SELFed, such thatthe outer cover (or said portions of the outer cover) comprises thepre-SELFed layer 18. An elastomeric layer 20 is then joined to thepre-SELFed layer to form the laminate. The elastomeric layer 20 may beany of the type discussed above, including but not limited to anelastomeric laminate layer 224.

Alternatively, as shown in FIG. 21b , the outer cover 526 a may bejoined to one or more elastomeric materials 22 and the resultingcombination can be activated, forming an elastomeric laminate layer 224which is an activated elastomeric material 222. One or more pre-SELFedcoverstock layer(s) 18 may then be joined to elastomeric laminate layer224, forming the laminate(s) 10.

Any configuration of the laminate 10 described herein may beincorporated into the backsheet to the extent workable. By incorporatinglaminates 10, the backsheet 526 becomes stretchable without the need toactivate through the total thickness of the backsheet.

As explained above, one or more edges of the laminate may be leftnon-elastomeric in order to more effectively secure said edge toadditional components of the article. Alternatively, the entire laminate10 in the backsheet may be elastomeric.

The laminate 10 may extend the maximum lateral and/or longitudinaldimensions of the backsheet. Alternatively, the laminate 10 may extendfor a portion of the longitudinal dimension of the article. The laminate10 may be present in one or more of the first waist region, second waistregion or crotch region. In a further embodiment, the laminate 10 mayextend for a portion, but not the entire width of the backsheet. Instill further embodiments, a laminate 20 may comprises edges that are atleast partially coterminous with lateral edges of the backsheet and/oredges that are at least partially coterminous with the longitudinaledges of the backsheet.

In some embodiments, as shown in FIGS. 21a-21b , two or more separatelaminates 10 are incorporated into the backsheet.

Although FIGS. 21a-21b depict an elastomeric layer 20 positioned abovethe outer cover 526 a, an elastomeric material 22 or elastomeric layer20 could be positioned below the outer cover 526 a (i.e., on thegarment-facing side 504 of the article). The laminate 10 may beincorporated into the backsheet in any workable fashion. Having theouter cover 526 a be a portion of the laminate 10 provides forstretchability while maximizing the impermeability features of the outercover. Further, the arrangement of the laminate in FIGS. 21a-21b (wherethe elastomeric layer is on the body facing side of the outer cover) mayalso provide a more desirable outer appearance, without any loose edgesof the laminate 10 being visible.

Because bonding may inhibit stretchability, the outer cover 526 a may bepartially unattached from the inner layer 526 b such that the outercover can extend independent of the inner layer 526 b and/or independentof the remaining article layers. The outer cover 526 a may be joined tothe inner layer 526 b by two or more attachment areas 600 havingdifferent dimensions. As can be seen in FIGS. 22a-b , a first attachmentarea 601 may comprises a first width, W1, and may be disposed at orproximate to a waist edge. The first width, W1, may extend for themajority of the width of the article; for example, the first width mayextend the majority of width of the inner layer 526 b, the majority ofthe width of the absorbent core, the majority of the width of thetopsheet and/or to a cuff edge 577. A second attachment area 602 may bedisposed longitudinally inboard of the first attachment area 601 and maycomprise a second width, W2. The second width, W2, may be less than thefirst width, W1. The narrower second attachment area minimizes thedampening effect that bonding has on the degree of extensibility ofcomponents of the article (e.g., the laminate 10, leg cuffs 570, etc.).

In some embodiments, an attachment area 600 joins a laminate 10 to theinner layer 526 b and/or to another layer of the article. In onenonlimiting example, the attachment area 600 overlaps or coincides withone or more edges of a laminate 10. In a further nonlimiting example,the second attachment area 602 joins the laminate to the inner layer 526b and/or to another layer. The backsheet may comprise further attachmentareas, including a third attachment area 603 that is narrower than thefirst and/or second attachment areas. Exemplary bonding methods forpartially attaching the outer cover to the inner layer can be found inU.S. Pat. Nos. 8,569,571, 8,124,828, and 5,575,783.

While a variety of backsheet configurations are contemplated herein, itwould be obvious to those skilled in the art that various other changesand modifications can be made without departing from the spirit andscope of the invention.

Ears/Fasteners:

The absorbent article 500 may include front ears 540 and/or back ears542 as shown in FIG. 20. The ears may be an integral part of thechassis, such as formed from the topsheet 524 and/or backsheet 526 asside panels. Alternatively, the ears may be separate elements attachedby gluing, heat embossing, and/or pressure bonding. Each ear may beextensible or inextensible. The ears 540, 542 may be formed fromnonwoven webs, woven webs, knitted fabrics, polymeric and elastomericfilms, apertured films, sponges, foams, scrims, and combinations andlaminates thereof. In some embodiments, the ear may include elastomers(e.g., elastic strands, LYCRA® fibers), such that the ear isstretchable. In certain embodiments, the ears may be formed of a stretchlaminate. One or more of the ears 540, 542 may comprise the laminate 10of the present disclosure.

The absorbent article 500 may also include a fastening system 544. Whenfastened, the fastening system 544 interconnects the first waist region536 and the rear waist region 538 resulting in a waist circumferencethat may encircle the wearer during wear of the absorbent article 20.The fastening system 544 may comprise a fastener 546 such as tape tabs,hook and loop fastening components, interlocking fasteners such as tabs& slots, buckles, buttons, snaps, and/or hermaphroditic fasteningcomponents, although any other known fastening means are generallyacceptable. Some exemplary surface fastening systems are disclosed inU.S. Pat. Nos. 3,848,594; 4,662,875; 4,846,815; 4,894,060; 4,946,527;5,151,092; and 5,221,274. An exemplary interlocking fastening system isdisclosed in U.S. Pat. No. 6,432,098. The fastening system 544 may alsoprovide a means for holding the article in a disposal configuration asdisclosed in U.S. Pat. No. 4,963,140. The fastening system 544 may alsoinclude primary and secondary fastening systems, as disclosed in U.S.Pat. No. 4,699,622. The fastening system 544 may be constructed toreduce shifting of overlapped portions or to improve fit as disclosed inU.S. Pat. Nos. 5,242,436; 5,499,978; 5,507,736; and 5,591,152. In someembodiments, the fastening system 544 and/or the fastener 546 isfoldable. In further embodiments, the fastening system comprises theelastomeric laminate 10 in accordance with the present disclosure.

Stretchable ears and/or fastening members may facilitate the attachmentof the fastening members to a landing zone and/or maintain the tapeddiapers in place around the wearer's waist. Further, extensible earsand/or fastening members may provide a more comfortable and contouringfit by initially conformably fitting the absorbent article to the wearerand sustaining this fit throughout the time of wear well past whenabsorbent article has been loaded with fluids or other bodily exudatessince the elasticized ears allow the sides of the absorbent article toexpand and contract.

Exemplary ears and/or fastening systems are disclosed in U.S. Pat. Nos.6,863,666; 6,132,411; 7,870,652; 8,992,499; 8,690,852; 8,382,736.

Leg Gasketing System

Turning to FIG. 21a , the absorbent article 500 may comprise a leggasketing system 570 attached to the chassis 22, which may comprise oneor more cuffs 571. The gasketing system may further comprise theelastomeric laminate 10 in order provide extensibility and one or moreof the afore-described benefits to a cuff 571.

The leg gasketing system may comprise a pair of barrier leg cuffs 572.Each barrier leg cuff may be formed by a piece of material which isbonded to the absorbent article so it may extend upwards from awearer-facing surface of the absorbent article and provide improvedcontainment of fluids and other body exudates approximately at thejunction of the torso and legs of the wearer. The barrier leg cuffs aredelimited by a proximal edge 574 joined directly or indirectly to thetopsheet 524 and/or the backsheet 526 and a free terminal edge 575,which is intended to contact and form a seal with the wearer's skin. Insome embodiments, the free terminal edge 575 comprises a folded edge asshown in FIGS. 21a-21b . The barrier leg cuffs 572 extend at leastpartially between the front waist edge 513 and the rear waist edge 514of the absorbent article on opposite sides of the longitudinal axis 510and are at least present in the crotch region. The barrier leg cuffs maybe joined at the proximal edge 574 with the chassis of the article by abond which may be made by gluing, fusion bonding, or a combination ofother suitable bonding processes.

The barrier leg cuffs may be integral with the topsheet 524 or thebacksheet 526 or may be a separate material joined to the article'schassis. Each barrier leg cuff 572 may comprise one, two or more elasticelements 555 close to the free terminal edge 575 to provide a betterseal. Additionally or alternatively, one or both of the barrier cuffs572 may comprise the elastomeric laminate 10.

In addition to the barrier leg cuffs 572, the article may comprisegasketing cuffs 576, which are joined to the chassis of the absorbentarticle, in particular to the topsheet 524 and/or the backsheet 526 andare placed externally relative to the barrier leg cuffs 572. Thegasketing cuffs 576 may provide a better seal around the thighs of thewearer. A gasketing cuff may comprise a proximal edge 578 and a freeterminal edge 577. The free terminal edge 577 may comprise a foldededge. Each gasketing cuff may comprise one or more elastic elements 555in the chassis of the absorbent article between the topsheet 524 andbacksheet 526 in the area of the leg openings. Additionally oralternatively, one or both of the gasketing cuffs 576 may comprise theelastomeric laminate 10. All, or a portion of, the barrier leg cuffsand/or gasketing cuffs may be treated with a lotion or another skin carecomposition.

In further embodiments, the leg gasketing system comprises barrier legcuffs that are integral with gasketing cuffs as depicted in FIGS. 21a-21 b.

Suitable leg gasketing systems which may be part of the absorbentarticle and/or modified to include the laminate of the present inventionare disclosed in U.S. Pat. App. No. 62/134,622, Ser. No. 14/077,708;U.S. Pat. Nos. 8,939,957; 3,860,003; 7,435,243; 8,062,279.

Elastic Waist Feature

The absorbent article 500 may comprise at least one elastic waistfeature 581 that helps to provide improved fit and containment, as shownin FIG. 20. The elastic waist feature 581 is generally intended toexpand and contract to dynamically fit the wearer's waist. In someembodiments, the laminate 10 can be used to provide extensibility and/orother benefits to the waist feature 581. Elasticized waist featuresinclude waistbands, waist cuffs having pockets formed from a portion ofthe waist feature 581 that is unattached from the chassis 522, and waistpanels designed to fit securely about the abdomen of the wearer.Nonlimiting examples of elasticized waist features are disclosed in U.S.patent application Ser. Nos. 13/490,543; 14/533,472; and 62/134,622.Waist features 581 may be joined to the chassis 522 in the first waistregion 536 and/or in the second waist region 538.

In some embodiments, the article 500 may comprise an absorbent pant 700as shown in FIGS. 23a-23b . The absorbent pant may comprise include achassis 522, a belt 720 to be positioned about the wearer's waist, andoptionally a leg gasketing system 570. FIG. 23b depicts an exemplaryprecursor structure of the pant in FIG. 23a , in an open configurationlaid out flat and stretched out laterally against elastic-inducedcontraction. In the final assembly of the pant, the front belt portion722 is joined to rear belt portion 723 at seams 724. The belt 720 may beelastomeric. Exemplary belt and absorbent pant constructions aredisclosed in U.S. patent application Ser. Nos. 14/598,783 and14/032,595. The belt may also include one or more fasteners. Whenfasteners are prefastened in the package, the product becomes arefastenable pant. If the fasteners are not prefastened, the product isa traditional taped diaper which includes a belt.

In some embodiments, the belt 720 may comprise one or more laminates 10of the present invention. In one nonlimiting example, one or both of thefront and rear belt portions comprise layers of coverstock material 17with an elastomeric material 22 sandwiched between the coverstocklayers. One or both of the coverstock layers may be pre-SELFed. Anyworkable configuration of a laminate 10 as disclosed herein may beincorporated into the belt 720, or into the absorbent pant 700.

Hip Panels

The article 500 may further comprise a stretchable hip panel 596positioned in the second waist region 538 and/or in the crotch region537 as shown in FIG. 20. Hip panels add stretch to the middle back ofthe article, permitting expansion of the back waist region and therebycreating a better fit about the hips and the buttocks of the wearer. Anexemplary hip panel is disclosed in U.S. Pat. No. 5,575,783. Theelastomeric laminate 10 of the present invention may be used in a hippanel to provide the desired extensibility and the afore-describedbenefits. In some embodiments, hip panels are formed by incorporatingone or more laminates into the backsheet as described in detail above.

Combinations

-   -   A. A method for forming an elastomeric laminate (10) that is        extensible in a first extensibility direction (FE) comprising        the steps of:        -   providing a first coverstock material (17);        -   activating the first coverstock material by passing the            first coverstock material under tension between the surfaces            of a pair of stretching members having discontinuously            intermeshing ridges and valleys, and thereby forming a            pre-activated layer (18) having a primary activation pattern            (28) comprising land areas (242) that extend in the first            extensibility direction;        -   providing an elastomeric layer (20); and        -   joining the elastomeric layer to the pre-activated layer at            one or more bonding sites (400).    -   B. The method of paragraph A wherein the elastomeric layer is        joined to the pre-activated layer at zero relative strain.    -   C. The method of paragraph A further comprising the steps:        -   elongating one of the elastomeric layer and the            pre-activated layer to form a strained layer such that            strained layer comprises a greater strain than the other of            elastomeric layer and the pre-activated layer; and        -   joining the elastomeric layer to the pre-activated layer,            such that the elastomeric layer and pre-activated coverstock            layer form a gathered laminate.    -   D. The method of paragraph C wherein the strained layer        comprises the elastomeric layer.    -   E. The method of paragraph C wherein the strained layer        comprises the pre-activated layer.    -   F. The method of any of paragraphs C-E wherein the elastomeric        layer and/or the pre-activated layer comprises a zero strain        laminate.    -   G. The method of any of the paragraphs A-E further comprising        the steps of providing a second coverstock material; activating        the second coverstock material to create a second pre-activated        coverstock layer having a secondary activation pattern; and        joining the second pre-activated coverstock layer to the        elastomeric layer and/or to the pre-activated coverstock layer.    -   H. The method of paragraph G wherein activating the second        coverstock comprises ringrolling the second coverstock material.    -   I. The method of paragraph G wherein activating the second        coverstock material is further characterized by passing the        second coverstock material under tension between the surfaces of        a pair of stretching members having discontinuously intermeshing        ridges and valleys.    -   J. The method of any of paragraphs G-I further comprising        offsetting the primary and secondary activation patterns.    -   K. The method of any of paragraphs A-J further comprising step        of aligning the one or more bonding sites with the primary        activation pattern.    -   L. The method of any of paragraphs A-K wherein the joining step        further comprises uniformly bonding the elastomeric layer to the        pre-activated layer.    -   M. The method of any of paragraphs A-K wherein the joining step        further comprises non-uniformly bonding the elastomeric layer to        the pre-activated layer.    -   N. The method of any of paragraphs A-M wherein in the step of        activating the first material, the pair of stretching members        comprises a uniform pattern.    -   O. The method of any of paragraphs A-M wherein in the step of        activating the first coverstock material, the pair of stretching        members comprises a nonuniform pattern.        Test Methods

Samples should be sufficient to provide for a gauge length of at least15 mm along the direction of stretch in the Test, and should be of aconstant width (perpendicular to the direction of stretch in the Test)of at least 5 mm. If the sample to be tested is joined to an article,cut if from the article. If testing a laminate, ensure that each layerof the laminate are present in the sample. If testing a layer of thelaminate (e.g., elastomeric layer), remove the remaining layers of thelaminate prior to testing the sample. Note, as discussed herein, thelaminate may be included in various components of an article. As such,the direction of stretch may vary based on the location of the sample inthe article. For example, the direction of stretch of leg cuffs is inthe longitudinal direction of the article while the direction of stretchin a waist feature is in the lateral direction of the article. If thesample is elastomeric or extensible in either the longitudinal or thelateral directions or both directions, it is within the scope of thepresent invention.

The Hysteresis Test can be used to various specified strain values. TheHysteresis Test utilizes a commercial tensile tester (e.g., from InstronEngineering Corp. (Canton, Mass.), SINTECH-MTS Systems Corporation (EdenPrairie, Minn.) or equivalent) interfaced with a computer. The computeris used to control the test speed and other test parameters and forcollecting, calculating, and reporting the data. The tests are performedunder laboratory conditions of 23° C.±2° C. and relative humidity of50%±2%. The samples are conditioned for 24 hours prior to testing.

Test Protocol

1. Select the appropriate grips and load cell. The grips must have flatsurfaces and must be wide enough to grasp the sample along its fullwidth. Also, the grips should provide adequate force to ensure that thesample does not slip during testing. The load cell is selected so thatthe tensile response from the sample tested is between 25% and 75% ofthe capacity of the load cell used.

2. Calibrate the tester according to the manufacturer's instructions.

3. Set the distance between the grips (gauge length) at 15 mm.

4. Place the sample in the flat surfaces of the grips such that theuniform width lies along a direction perpendicular to the gauge lengthdirection. Secure the sample in the upper grips, let the sample hangslack, then close the lower grips. Set the slack preload at 0.02 N/cm.This means that the data collection starts when the slack is removed (ata constant crosshead speed of 10 mm/min) with a force of 0.02 N/cm.Strain is calculated based on the adjusted gauge length (l_(ini)), whichis the length of the sample in between the grips of the tensile testerat a force of 0.02 N/cm. This adjusted gauge length is taken as theinitial sample length, and it corresponds to a strain of 0%. Percentstrain at any point in the test is defined as the change in lengthdivided by the adjusted gauge length times 100.

5(a) First cycle loading: Pull the sample to the specified strain(herein, 25%) at a constant cross head speed of 100 mm/min. Report thestretched sample length between the grips as l_(max).

5(b) First cycle unloading: Hold the sample at the specified strain for30 seconds and then return the crosshead to its starting position (0%strain or initial sample length, l_(ini)) at a constant cross head speedof 100 mm/min. Hold the sample in the unstrained state for 1 minute.

5(c) Second cycle loading: Pull the sample to the specified strain at aconstant cross head speed of 100 mm/min.

5(d) Second cycle unload: Next, return the crosshead to its startingposition (i.e. 0% strain) at a constant cross head speed of 100 mm/min.

A computer data system records the force exerted on the sample duringthe test as a function of applied strain. From the resulting datagenerated, the following quantities are reported (note that loads arereported as force divided by the width of the sample and do not takeinto account the thickness of the sample):

i. Length of sample between the grips at a slack preload of 0.02 N/cm(l_(ini)) to the nearest 0.001 mm.

ii. Length of sample between the grips on first cycle at the specifiedstrain (l_(max)) to the nearest 0.001 mm.

iii. Length of sample between the grips at a second cycle load force of0.02 N/cm (l_(ext)) to the nearest 0.001 mm.

iv. % set, which is defined as (l_(ext)−l_(ini))/(l_(max)−l_(ini))*100%to the nearest 0.01%.

The testing is repeated for six separate samples and the average andstandard deviation reported.

The Hysteresis Test can be suitably modified depending on the expectedattributes and/or properties of the particular material sample to bemeasured. For example, where a sample of the length and width specifiedabove are not available from the subject article, the crosshead speed isadjusted to maintain the same strain rate as that which would beachieved using a 15 mm gauge length and 100 mm/min crosshead speed. Asanother example, the specified strain may be changed to determineelasticity at different strain levels. In some embodiments, thespecified strain is about 50% or more, or about 100% or more, or fromabout 25% to about 200%, reciting for each range every 10% incrementtherein.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application and any patent application or patent to which thisapplication claims priority or benefit thereof, is hereby incorporatedherein by reference in its entirety unless expressly excluded orotherwise limited. The citation of any document is not an admission thatit is prior art with respect to any invention disclosed or claimedherein or that it alone, or in any combination with any other referenceor references, teaches, suggests or discloses any such invention.Further, to the extent that any meaning or definition of a term in thisdocument conflicts with any meaning or definition of the same term in adocument incorporated by reference, the meaning or definition assignedto that term in this document shall govern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A method for forming an elastomeric laminatecomprising the steps of: providing a first coverstock material; SELF'ingthe first coverstock material to create a pre-SELFed coverstock layerhaving a primary activation pattern comprising SELF-specific land areasand deformed areas; providing an elastomeric layer; and joining theelastomeric layer at zero strain to the pre-SELFed layer in a relaxedstate wherein the deformed areas exist, such that the elastomeric layerand pre-SELFed coverstock layer are joined at one or more bonding sites.2. The method of claim 1 further comprising the steps of providing asecond coverstock material; activating the second coverstock material tocreate a second pre-activated coverstock layer having a secondaryactivation pattern; and joining the second pre-activated coverstocklayer to the elastomeric layer and/or to the pre-SELFed coverstocklayer.
 3. The method of claim 2 wherein activating the second coverstockmaterial further comprises SELF'ing the second coverstock material. 4.The method of claim 2 further comprising offsetting the primary andsecondary activation patterns.
 5. The method of claim 1 wherein thejoining step is achieved by one of adhesive, thermal bonding, and/ormechanical bonding.
 6. The method of claim 1 wherein the joining stepfurther comprises uniformly bonding the elastomeric layer to thepre-SELFed coverstock layer.
 7. The method of claim 1 further comprisingthe step of aligning the one or more bonding sites with the primaryactivation pattern.
 8. The method of claim 1 wherein the joining stepfurther comprises non-uniformly bonding the elastomeric layer to thepre-SELFed coverstock material.
 9. The method of claim 1 wherein theSELF'ing step further comprises SELF'ing the first coverstock materialwith a uniform SELF pattern.
 10. The method of claim 1 wherein theSELF'ing step further comprises SELF'ing the first coverstock materialwith a nonuniform SELF pattern.
 11. A method for forming an elastomericlaminate comprising the steps of: providing a first coverstock material;SELF'ing the first coverstock material to create a pre-SELFed coverstocklayer having a primary activation pattern comprising SELF-specific landareas; providing an elastomeric layer; elongating one of the elastomericlayer and the pre-SELFed layer to form a strained layer such thatstrained layer comprises a greater strain than the other of elastomericlayer and the pre-SELFed layer; and joining the elastomeric layer to thepre-SELFed layer, such that the elastomeric layer and pre-SELFedcoverstock layer are joined at one or more bonding sites and form agathered laminate.
 12. The method of claim 11 wherein the strained layercomprises the elastomeric layer.
 13. The method of claim 11 wherein thestrained layer comprises the pre-SELFed coverstock layer.
 14. The methodof claim 11 further comprising the steps of providing a secondcoverstock material; activating the second coverstock material to createa second pre-activated coverstock layer having a secondary activationpattern; and joining the pre-activated second coverstock layer to theelastomeric layer and/or to the pre-SELFed coverstock layer.
 15. Themethod of claim 14 wherein activating the second coverstock materialfurther comprises SELF'ing the second coverstock material.
 16. Themethod of claim 11 wherein the joining step further comprises uniformlybonding the elastomeric layer to the pre-SELFed coverstock layer. 17.The method of claim 11 further comprising the step of aligning the oneor more bonding sites with the primary activation pattern.
 18. Themethod of claim 11 wherein the joining step further comprisesnon-uniformly bonding the elastomeric layer to the pre-SELFed coverstockmaterial.
 19. The method of claim 11 wherein the SELF'ing step furthercomprises SELF'ing the first coverstock material with a uniform SELFpattern.
 20. The method of claim 11 wherein the SELF'ing step furthercomprises SELF'ing the coverstock material with a nonuniform SELFpattern.